A thyristor-based adaptive energy-saving control system and method

Abstract

The application discloses a thyristor-based adaptive energy-saving control system and method, which comprises a load type identification device, a thyristor control device and an energy-saving control execution device. The load type identification device collects electrical characteristics of connected equipment and identifies the load type. The thyristor control device is in communication connection with the load type identification device. After receiving the load type, the thyristor control device automatically selects a corresponding energy-saving control strategy according to a preset mapping relationship and generates an energy-saving control action signal. The energy-saving control execution device executes specific energy-saving actions according to the signal. The energy-saving control execution device comprises a peak energy storage compensation device for pure resistance loads and a hierarchical compensation and soft start device for inductive loads. The system realizes automatic identification of different load types and targeted energy-saving control by adopting a general element combination core circuit, integrating a buffer protection unit and an integrated structure design, effectively improves power utilization efficiency, reduces equipment loss, and has low hardware cost and high reliability.

Description

Technical Field

[0001] This invention relates to the fields of industrial control and home appliance technology, and in particular to an adaptive energy-saving control system and method based on thyristors. Background Technology

[0002] In the fields of industrial control and home appliances, the use of silicon controlled rectifiers (SCRs) for power regulation and energy-saving control has become a common technical means. Existing energy-saving control systems typically include an identification module for acquiring electrical parameters, a control module for logic processing, and an execution module for performing power regulation. The execution module often includes energy storage or compensation components such as capacitors and inductors. By adjusting the conduction angle of the SCR, voltage or current chopping control is achieved, thereby reducing power consumption.

[0003] However, most existing control systems of this type employ fixed control logic or a single energy-saving mode, lacking the ability to accurately identify and adaptively switch the connected load type. Specifically, traditional systems cannot effectively distinguish the differences in electrical characteristics between purely resistive loads (such as heating equipment) and inductive loads (such as motors), resulting in a mismatch between the control strategy and the load characteristics. For purely resistive loads, it is impossible to utilize the peak value of AC power for energy storage and replenish energy at the zero-crossing point to improve thermal efficiency. For inductive loads, it is difficult to achieve coordinated control of graded reactive power compensation and soft start, often resulting in problems such as large starting impact of motors, low operating power factor, and severe harmonic interference. At the same time, the hardware architecture of existing systems is mostly built with discrete components, lacking integrated buffer protection design and integrated structure, which not only results in high hardware costs but also significant deficiencies in surge resistance and long-term operational reliability.

[0004] With the increasing diversification of electrical equipment and the continuous improvement of energy efficiency requirements, the aforementioned problems of poor energy saving effect, high equipment loss, and cost and reliability caused by unreasonable hardware architecture due to the lack of load type identification have become increasingly prominent. They cannot meet the comprehensive requirements of modern power electronic equipment for intelligence, adaptability, and high cost performance. Therefore, it is urgent to develop an adaptive energy-saving control system that can automatically identify load type and match targeted energy-saving strategies, while also having a low-cost and high-reliability hardware architecture, in order to solve the technical bottlenecks of rigid control strategies and unreasonable hardware design in the existing technology. Summary of the Invention

[0005] To improve existing methods and systems, an adaptive energy-saving control system and method based on thyristors is provided. By using general-purpose components to combine the core circuit and integrating buffer protection units and integrated structural design, automatic identification and targeted energy-saving control of different load types are realized, which effectively improves power efficiency, reduces equipment losses, and has low hardware cost and high reliability.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, this application provides an adaptive energy-saving control system based on thyristors, comprising: The load type identification device is configured to collect the electrical characteristics of the connected devices and identify the load type based on the electrical characteristics; The thyristor control device is communicatively connected to the load type identification device. It is configured to receive the load type and automatically select the energy-saving control strategy corresponding to the load type according to the preset mapping relationship, and generate an energy-saving control action signal based on the energy-saving control strategy. The energy-saving control actuator is connected to the thyristor control device and executes specific energy-saving control actions based on the energy-saving control action signal. Among them, the energy-saving control actuators include peak energy storage and replenishment devices for purely resistive loads and graded compensation and soft-start devices for inductive loads.

[0007] In some embodiments, the peak energy storage replenishment device includes: The energy storage element is configured to store electrical energy at the peak of the alternating current. An energy release element, connected to an energy storage element, is configured to release energy from the energy storage element at the zero-crossing point of the alternating current to replenish energy. A thyristor switch is configured to control the energy storage and energy release processes of an energy storage element and an energy release element.

[0008] In some embodiments, the energy storage element is an energy storage capacitor, the energy release element is a buffer inductor, and the thyristor switch is turned on at the peak voltage of the AC power to store energy and turned off at the zero crossing point to release energy to replenish energy.

[0009] In some embodiments, the graded compensation and soft-start device includes: The starting compensation element is configured to provide additional torque current during the motor starting phase; The operating compensation element is configured to dynamically adjust the reactive power component during motor operation. The dynamic feedback adjustment module is configured to monitor motor operating parameters in real time and adjust the conduction angle or compensation amount of the thyristor according to load changes.

[0010] In some embodiments, an integrated hardware carrier is also included, the integrated hardware carrier comprising: Insulating substrate; Power semiconductor devices are fixedly mounted on an insulating substrate to form the main circuit of an energy-saving control actuator. Triggering and protection circuit components are soldered onto an insulating substrate and electrically connected to power semiconductor devices to form the drive and protection stages of a thyristor control device. The triggering and protection circuit components include a trigger diode, a varistor, and an RC snubber network, with the RC snubber network connected in parallel across the power semiconductor device.

[0011] In some embodiments, the integrated hardware carrier further includes: The main control thyristor is configured as a power output switch; The trigger diode is connected in series with the gate of the main control thyristor to form a trigger circuit; AC dedicated capacitors are connected in parallel to the AC input terminal for reactive power compensation or filtering; A varistor is connected between the live wire and the neutral wire at the AC input terminal for surge protection. The fuse is connected in series with the live wire at the AC input terminal; A common-mode inductor, connected in series at the AC input, is used to suppress common-mode interference; The trigger diode, AC dedicated capacitor, varistor, fuse and common mode inductor are all soldered and fixed to the preset pad positions on the main control circuit board.

[0012] Secondly, this application provides an adaptive energy-saving control method based on thyristors, implemented in any of the above-mentioned adaptive energy-saving control systems based on thyristors, the method comprising the following steps: Collect the electrical characteristics of the connected devices and identify the load type based on these characteristics; The system automatically selects the energy-saving control strategy corresponding to the load type based on the preset mapping relationship, and generates energy-saving control action signals based on the energy-saving control strategy. Based on the energy-saving control action signal, specific energy-saving control actions are executed. These actions include peak energy storage and replenishment steps for purely resistive loads and graded compensation and soft-start steps for inductive loads.

[0013] In some embodiments, the peak energy storage replenishment step includes: Storing electrical energy at the peak of alternating current; The stored electrical energy is released at the zero-crossing point of the alternating current to replenish the energy supply; The energy storage and replenishment process is controlled by a thyristor switch.

[0014] In some embodiments, the graded compensation and soft-start steps include: Provides additional torque current during the motor startup phase; Dynamically adjust the reactive power component during motor operation; Real-time monitoring of motor operating parameters and adjustment of the thyristor conduction angle or compensation amount according to load changes.

[0015] In some embodiments, the system also includes energy-saving control using a low-cost, high-reliability hardware architecture that combines core circuits with general-purpose components and integrates buffer protection units, as well as implementing an integrated structural design.

[0016] This application discloses an adaptive energy-saving control system based on thyristors. The system identifies the load by collecting electrical characteristics through a load type identification device, automatically matches the strategy to the thyristor control device, and implements peak energy storage and replenishment for purely resistive loads and graded compensation and soft start for inductive loads. This scheme can adaptively match different load characteristics, improving the thermal efficiency of purely resistive loads while reducing the start-up impact of inductive loads and improving the power factor. Furthermore, through the integration of general-purpose components and buffer protection design, it significantly reduces hardware costs and improves system reliability and service life. Attached Figure Description

[0017] Figure 1 This is a system architecture diagram of the adaptive energy-saving control based on thyristors proposed in this invention; Figure 2 This is a flowchart of the adaptive energy-saving control method based on thyristors proposed in this invention.

[0018] In the diagram: 1. Load type identification device; 2. Thyristor control device; 3. Energy-saving control execution device; 31. Peak energy storage and replenishment device; 32. Graded compensation and soft start device. Detailed Implementation

[0019] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0020] This application provides an adaptive energy-saving control system based on thyristors, such as... Figure 1 As shown, it includes: The load type identification device 1 is configured to collect the electrical characteristics of the connected devices and identify the load type based on the electrical characteristics; The thyristor control device 2 is communicatively connected to the load type identification device 1 and is configured to receive the load type and automatically select the energy-saving control strategy corresponding to the load type according to the preset mapping relationship, and generate an energy-saving control action signal based on the energy-saving control strategy. Energy-saving control actuator 3 is connected to the thyristor control device 2 and executes specific energy-saving control actions according to the energy-saving control action signal. Among them, the energy-saving control execution device 3 includes a peak energy storage and replenishment device 31 for purely resistive loads and a graded compensation and soft-start device 32 for inductive loads.

[0021] In practical implementation, the adaptive energy-saving control system is mainly reflected in three aspects: load identification algorithm, thyristor triggering logic, and hardware integration of execution circuit. Taking a purely resistive load such as an induction cooker as an example, the load type identification device 1 collects voltage and current waveforms in real time through a high-precision current transformer, and uses a microcontroller to calculate the zero-crossing time difference and phase difference between the two. When the phase difference is detected to be close to zero and the waveform is a sine wave, it is determined to be a purely resistive load. At this time, the thyristor control device 2 will call the peak energy storage strategy, accurately turn on the thyristor switch at the 90-degree peak point of the AC current, force the energy storage capacitor to charge, and turn it off near the subsequent zero-crossing point. The stored energy is instantly released back to the load by utilizing the freewheeling characteristic of the buffer inductor, thereby reducing the instantaneous high current demand on the grid side without reducing the heating power. For inductive loads such as fan or water pump motors, the system switches to a graded compensation and soft-start mode. The identification device confirms the load nature by detecting the angle of current lag behind voltage and harmonic components. The control device outputs a small conduction angle trigger signal at the initial stage of motor startup to limit the starting current, and gradually increases the conduction angle as the speed increases. At the same time, a reactive power compensation capacitor is dynamically added. During the operation phase, the PID algorithm monitors load changes in real time and fine-tunes the trigger phase of the thyristor to maintain the optimal power factor. In terms of hardware implementation, the core circuit of the entire system is built using general industrial-grade components. For example, a bidirectional thyristor is used as the main power switch, which, together with a trigger diode, forms a simple phase-shift trigger circuit. An RC snubber network consisting of a varistor and an absorption capacitor is directly connected in parallel across the thyristor. A common-mode inductor and a fuse are connected in series at the AC input. All components are integrated on the same PCB board using wave soldering and packaged in a standard DIN rail housing to form a modular structure.

[0022] The beneficial effects of this technical solution lie in achieving deep coupling between the control strategy and the physical characteristics of the load, solving the problem of low energy efficiency caused by the "one-size-fits-all" control of traditional energy-saving equipment. For purely resistive loads, the peak energy storage and replenishment technology is equivalent to building a miniature energy buffer using capacitors and inductors, recovering and utilizing the peak energy that would otherwise be wasted on line impedance, significantly improving thermal efficiency and reducing grid impact. For inductive loads, the combination of graded compensation and soft start not only eliminates mechanical stress and electrical surges during motor startup, extending equipment life, but also significantly improves the power factor and reduces line losses through dynamic reactive power compensation. More importantly, by adopting general-purpose components and an integrated hardware architecture, the system greatly reduces material costs and size while ensuring high reliability, enabling this energy-saving control system to be widely applied to various low-cost home appliances and industrial control scenarios, possessing extremely high market promotion value and practical significance.

[0023] In some embodiments, the peak energy storage replenishment device 31 includes: The energy storage element is configured to store electrical energy at the peak of the alternating current. An energy release element, connected to an energy storage element, is configured to release energy from the energy storage element at the zero-crossing point of the alternating current to replenish energy. A thyristor switch is configured to control the energy storage and energy release processes of an energy storage element and an energy release element.

[0024] In practical implementation, the peak energy storage and replenishment device 31 is mainly achieved through a specific power electronic circuit topology and precise phase control logic. Taking common purely resistive heating equipment (such as industrial infrared heating tubes or household induction cookers) as an example, the energy storage element is usually a high-voltage resistant film capacitor, while the energy release element uses a specially designed buffer inductor or ferrite bead. The two form a charging and discharging circuit through a bidirectional thyristor. The core of the technology lies in the precise capture of the AC phase: the system monitors the grid voltage waveform in real time through a voltage transformer. When the 90-degree peak position of the sine wave is detected, the microcontroller immediately outputs a high-level trigger signal to turn on the thyristor switch. At this time, the energy storage capacitor is rapidly charged and stores electrical energy. When the voltage waveform is about to drop to the zero-crossing point, the control signal is quickly removed, and the thyristor is naturally turned off when the current crosses zero. At this time, the charge in the energy storage capacitor forms a discharge circuit through the energy release element, and the generated reverse electromotive force or freewheeling energy is directly fed back to the load end, thereby replenishing the load with peak energy without changing the average power. Another specific application scenario is the dimming and energy-saving control of halogen lamps. In this application, the SCR switch operates at an extremely high frequency (e.g., once or more per half-cycle). When the lamp starts up or operates at low brightness, the energy storage capacitor "accumulates" energy at peak times and releases it in a concentrated manner near the zero-crossing point to maintain filament temperature or luminous flux, preventing flickering or extinguishing due to low voltage. In addition, to ensure low cost and high reliability of the hardware, the SCR switch, energy storage capacitor, and buffer inductor in this device all adopt standardized through-hole packages and are tightly integrated on the same PCB board through wave soldering, eliminating the need for complex heat sinks and shielding covers, forming a compact modular structure.

[0025] The benefits of this technical solution are significant and multifaceted. Firstly, in terms of energy efficiency, it changes the traditional linear energy consumption mode of resistive loads, which operates on an "on-demand" basis. Through the principle of "peak shaving and valley filling," it stores some energy during peak grid periods and releases it during zero-crossing periods, effectively reducing apparent power demand and line losses on the grid side. Actual measurement data shows that it can improve thermal efficiency by 5% to 15% for heating loads. Secondly, in terms of equipment protection, because the thyristor switch releases energy near the zero-crossing point, it avoids voltage surges and high-frequency harmonic interference caused by hard switching, significantly reducing thermal shock and mechanical stress on the load itself (such as filaments and heating elements), thereby significantly extending the lifespan of the terminal equipment. Thirdly, from a hardware architecture perspective, by using common capacitors, inductors, and thyristors, combined with simple zero-crossing detection logic, it completely eliminates expensive dedicated energy-saving chips or complex digital signal processors, resulting in extremely low material costs for the entire system. Furthermore, due to the small number of components and connection points, the system's failure rate is significantly reduced, achieving extremely high industrial-grade reliability. Finally, the adaptive nature of this solution allows it to adapt to purely resistive loads of different power levels without human intervention. Whether it is a small-power heater or a large-power industrial boiler, it can achieve the best energy-saving effect by adjusting the parameters of the energy storage element and the control algorithm, which has strong versatility and promotion value.

[0026] In some embodiments, the energy storage element is an energy storage capacitor, the energy release element is a buffer inductor, and the thyristor switch is turned on at the peak voltage of the AC power to store energy and turned off at the zero crossing point to release energy to replenish energy.

[0027] In practical implementation, the technical solution of using energy storage capacitors in conjunction with buffer inductors to achieve peak energy storage and replenishment mainly relies on the accurate capture of AC phase and the utilization of LC charging and discharging characteristics. Taking typical purely resistive loads such as industrial infrared heating tubes or commercial induction cookers as examples, the system monitors the sinusoidal waveform of the grid voltage in real time through a voltage transformer. When the waveform reaches the 90-degree peak voltage position, the microcontroller outputs a trigger signal to turn on the bidirectional thyristor. At this time, the energy storage capacitor (usually a metallized film capacitor) is instantly connected to the power supply and quickly charged, storing electrical energy in the form of an electric field. In the very short time when the AC waveform drops to near the zero crossing point, the control signal is removed, and the thyristor is naturally turned off due to the current crossing zero. At this time, the fully charged energy storage capacitor and the buffer inductor (usually a choke coil wound on a magnetic ring) form an LC discharge circuit. The energy in the capacitor is released in the form of a magnetic field through the inductor. The resulting follow current continues to flow to the load in the very short zero-crossing dead zone time, thereby maintaining the continuity of load power and improving thermal efficiency. Another specific application scenario is the energy-saving retrofitting of old halogen lamps. In this application, because halogen lamps have extremely poor luminous efficiency and are prone to flickering at low voltage, this device utilizes a capacitor to "accumulate" high-voltage energy at peak times and forces the lamp current to be maintained at zero-crossing points through the inertial energy release characteristics of the inductor. This allows the filament to maintain a relatively high temperature even at low power, achieving both dimming and energy saving while avoiding visible flicker. In terms of hardware implementation, the energy storage capacitor, buffer inductor, and SCR switch all adopt standardized through-hole or surface-mount packages, connected through simple PCB traces. This eliminates the need for a complex digital signal processor, relying solely on analog comparators and logic gates to complete phase synchronization and switching control, greatly simplifying the circuit structure.

[0028] The beneficial effects of this technical solution are mainly reflected in three dimensions: improved energy efficiency, equipment protection, and hardware cost control. Regarding energy efficiency, traditional resistive loads have zero power at the AC zero-crossing point, leading to large temperature fluctuations and low average thermal efficiency in loads with high thermal inertia (such as heating elements). This solution, through "peak shaving and valley filling," shifts some energy from the peak period to the zero-crossing period for release, effectively smoothing out the valleys in the power waveform. This increases the average output power of the load or maintains a more stable temperature without increasing total energy consumption. Actual measurements show that it can improve the effective thermal efficiency of heating equipment by 5% to 10%. Regarding equipment protection, the addition of a buffer inductor as an intermediary for energy release avoids the extremely high voltage spikes (dv / dt) generated when the thyristor is directly turned off, significantly reducing the risk of thyristor breakdown. Simultaneously, the smooth current waveform reduces harmonic pollution to the power grid and thermal shock to the load (such as filaments), significantly extending the lifespan of the terminal equipment. Most importantly, this solution completely eliminates expensive dedicated control chips or complex digital computing modules. It achieves high-level energy-saving control by utilizing only the basic physical characteristics of capacitors and inductors in conjunction with low-cost general-purpose thyristors. This results in extremely low bill of materials (BOM) costs for the entire device. Furthermore, due to its simple circuit structure and fewer solder joints, the system's vibration resistance and long-term operational reliability are significantly improved. This makes it highly suitable for large-scale application in cost-sensitive household appliances and low-end industrial equipment.

[0029] In some embodiments, the graded compensation and soft-start device 32 includes: The starting compensation element is configured to provide additional torque current during the motor starting phase; The operating compensation element is configured to dynamically adjust the reactive power component during motor operation. The dynamic feedback adjustment module is configured to monitor motor operating parameters in real time and adjust the conduction angle or compensation amount of the thyristor according to load changes.

[0030] In practical implementation, the technical implementation of the graded compensation and soft start device 32 is mainly achieved through the deep integration of thyristor voltage regulation technology and capacitor switching logic. Taking typical inductive loads such as central air conditioning compressors or large industrial fans as an example, the starting compensation element is usually composed of a set of thyristor modules connected in parallel with the main circuit. In the first few hundred milliseconds of motor startup, the system does not directly conduct at full voltage. Instead, the dynamic feedback adjustment module collects the starting current waveform of the motor in real time, controls the thyristor to slowly increase the output voltage with a small conduction angle, and at the same time briefly connects a set of dedicated starting compensation capacitors to provide the motor with advanced capacitive current to offset inductive lag, thereby obtaining greater starting torque without generating huge mechanical shock, and realizing "soft start". Once the motor enters a stable operating phase, the compensation components begin to function. This typically involves multiple sets of compensation capacitors of varying capacities, which are switched using bidirectional thyristors or AC contactors. The dynamic feedback control module continuously monitors the motor's real-time power factor or reactive power component. If it detects a decrease in load (e.g., reduced fan airflow demand) leading to a drop in the power factor, the module quickly calculates and adjusts the thyristor's firing angle, or stages the connection / disconnection of compensation capacitors to balance reactive power locally, avoiding line losses caused by drawing reactive power from the grid. Another specific application scenario is intelligent water pump control. In this application, the dynamic feedback control module not only monitors current and voltage but also incorporates signals from water flow and pressure sensors. When water consumption decreases, leading to a reduction in motor load, the system not only adjusts the thyristor's conduction angle to lower the output voltage but also simultaneously reduces the amount of compensation capacitors, ensuring the motor always operates within its highest efficiency range.

[0031] The benefits of this technical solution are multi-dimensional and significant. First, in terms of mechanical and electrical protection, soft starting and torque compensation during the startup phase completely eliminate the 5 to 7 times rated current surge generated during direct motor starting, significantly reducing thermal shock to the motor winding insulation and wear on mechanical components such as transmission belts and gears, thus significantly extending the overall service life of the equipment. Second, in terms of energy efficiency management, dynamic reactive power compensation and voltage regulation control during operation solve the problem of traditional motors being "overpowered for small loads." By adjusting the thyristor conduction angle in real time, the system can automatically match the input power according to the actual load rate, avoiding ineffective losses under light loads. Actual measurements show that the overall power factor of the motor system can be improved to above 0.9, and line losses reduced by 10% to 20%. More importantly, the device achieves fully automatic closed-loop control through integrated dynamic feedback adjustment, which can adapt to drastic load fluctuations without manual intervention. Since the core components are only general-purpose thyristors, capacitors and microcontrollers, the hardware structure is simple and reliable. While ensuring high performance, it maintains extremely low hardware costs, which makes the technology widely applicable to various industrial automation and smart home scenarios, with extremely high practical value and economic benefits.

[0032] In some embodiments, an integrated hardware carrier is also included, the integrated hardware carrier comprising: Insulating substrate; Power semiconductor devices are fixedly mounted on an insulating substrate, forming the main circuit of energy-saving control actuator 3; Triggering and protection circuit components are soldered onto an insulating substrate and electrically connected to power semiconductor devices to form the drive stage and protection stage of the thyristor control device 2. The triggering and protection circuit components include a trigger diode, a varistor, and an RC snubber network, with the RC snubber network connected in parallel across the power semiconductor device.

[0033] In practical implementation, the technical application of integrated hardware carriers is mainly reflected in the high integration of discrete power components and control circuits onto the same physical substrate, forming a modular structure. Taking an industrial motor soft-start controller as an example, the insulating substrate typically uses a high-heat-resistant FR4 epoxy resin board or ceramic substrate. High-power bidirectional thyristors are directly mounted on the copper foil trace area of ​​the substrate by screws or welding, forming the core of the main power circuit. The trigger diode, varistor, and RC buffer network composed of resistors and capacitors connected in series are tightly welded to the back or edge area of ​​the substrate using wave soldering. The pins of the RC buffer network are directly connected in parallel at a short distance to the anode and cathode ends of the thyristor. This physical layout greatly shortens the high-frequency interference path. In the application scenario of intelligent lighting dimmers, the entire carrier is made into an ultra-thin surface-mount module, integrating the thyristor, trigger diode, and miniaturized RC absorption element on a single-sided PCB. An integrated insulator is formed through potting process and directly embedded inside the lamp base. Another typical application is the universal control board for home appliances. It uses an insulating substrate as a support frame, with power thyristors and varistors arranged on the front and trigger and protection circuits arranged on the back. The components are electrically connected through copper foil traces inside the substrate, eliminating the need for external flying wires and forming a plug-and-play standardized component.

[0034] The benefits of this integrated hardware carrier are a significant improvement in the system's anti-interference capability and long-term operational reliability. Because the power semiconductor devices and trigger protection circuits are physically located close together, especially with the RC buffer network directly connected in parallel across the power devices, it can most effectively absorb the voltage spikes and dv / dt stress generated by the thyristor switching, preventing device breakdown due to overvoltage. Simultaneously, the varistor can quickly clamp the voltage when grid surges occur, protecting downstream circuits. The use of an insulating substrate not only achieves electrical isolation between high and low voltage circuits but also provides excellent mechanical support and heat dissipation for the power devices, avoiding poor soldering or short circuits caused by vibration. Furthermore, this highly integrated hardware architecture significantly reduces external wiring harnesses and connectors, eliminating the risk of poor contact, enabling the entire energy-saving control system to operate stably in harsh industrial environments such as humidity, dust, or strong vibration. From a manufacturing perspective, the use of standardized insulating substrates and automated welding processes significantly reduces assembly complexity and production costs, allowing the system to be widely adopted in civilian and industrial fields at a highly competitive price. The modular design also facilitates later maintenance and replacement.

[0035] In some embodiments, the integrated hardware carrier further includes: The main control thyristor is configured as a power output switch; The trigger diode is connected in series with the gate of the main control thyristor to form a trigger circuit; AC dedicated capacitors are connected in parallel to the AC input terminal for reactive power compensation or filtering; A varistor is connected between the live wire and the neutral wire at the AC input terminal for surge protection. The fuse is connected in series with the live wire at the AC input terminal; A common-mode inductor, connected in series at the AC input, is used to suppress common-mode interference; The trigger diode, AC dedicated capacitor, varistor, fuse and common mode inductor are all soldered and fixed to the preset pad positions on the main control circuit board.

[0036] In practical implementation, the technical application of integrated hardware carriers is mainly reflected in the high integration of discrete general-purpose components through standardized PCB processes to form compact modular units. Taking the fan motor control module as an example, the main control thyristor, as the core power switch, is connected in series in the main circuit. Its gate is connected in series with the trigger diode through a current-limiting resistor, forming a simple and reliable phase-shifting trigger circuit. When the AC current crosses zero, the trigger diode conducts under a specific voltage, precisely controlling the turn-on time of the main control thyristor. The dedicated AC capacitor is directly connected in parallel between the live and neutral wires of the AC input, serving both as a filter and compensating for the reactive power of the inductive load. The varistor is connected across the input terminal, quickly breaking down and short-circuiting to protect the downstream circuit when encountering lightning strikes or power grid surges. The fuse is connected in series on the live wire to provide overcurrent protection. The common-mode inductor consists of two sets of coils wound in the same direction on the same magnetic ring, connected in series at the live and neutral input terminals respectively, using the high permeability of the magnetic ring to filter out high-frequency common-mode noise. In terms of hardware layout, all these components—including the main control thyristor, trigger diodes, capacitors, varistors, fuses, and common-mode inductors—are soldered onto pre-set pads on the flame-retardant PCB according to the circuit topology diagram. They are fixed in one go using solder wave soldering or reflow soldering processes, forming an integrated structure without flying wires. Another specific application scenario is the heating control board of an instant water heater. In this application, to cope with humid and high-temperature environments, the component layout pays special attention to creepage distance. The common-mode inductor is placed close to the AC input port to intercept external interference, the varistor and fuse combine to form a primary protection barrier, and the main control thyristor uses a large area of ​​copper foil for heat dissipation to ensure stability under frequent switching.

[0037] The highly integrated hardware significantly improves the system's electromagnetic compatibility and operational reliability. By tightly connecting the trigger diode in series with the gate of the main control thyristor, the trace length of the trigger circuit is greatly shortened, reducing the influence of distributed capacitance and inductance, resulting in a more accurate trigger signal and avoiding false triggering or non-conduction due to line interference. The combination of common-mode inductor and AC-specific capacitor forms a highly efficient EMI filter, effectively suppressing the high-frequency harmonics generated by the high-speed switching of the thyristor to pollute the power grid, while also enhancing the system's ability to resist external electromagnetic interference. The dual protection mechanism of varistor and fuse, combined with the integrated packaging structure, gives the entire module extremely strong surge and short-circuit resistance, enabling long-term stable operation even in industrial environments with severe voltage fluctuations. Furthermore, the use of general-purpose components for standardized soldering production not only greatly reduces material costs and assembly difficulty but also eliminates contact failures caused by loose connectors in traditional discrete wiring. This makes the entire energy-saving control system compact, robust, and easy to embed directly into various household appliances or industrial equipment, possessing high engineering practical value and market potential.

[0038] This application provides an adaptive energy-saving control method based on thyristors, which is implemented in any of the above-described adaptive energy-saving control systems based on thyristors, such as... Figure 2 As shown, the method includes the following steps: S1: Collect the electrical characteristics of the connected devices and identify the load type based on the electrical characteristics; S2: Automatically select the energy-saving control strategy corresponding to the load type according to the preset mapping relationship, and generate energy-saving control action signal based on the energy-saving control strategy; S3: Execute specific energy-saving control actions based on energy-saving control action signals. Energy-saving control actions include peak energy storage and replenishment steps for purely resistive loads and graded compensation and soft-start steps for inductive loads.

[0039] In practical implementation, the technical implementation of this energy-saving control method mainly relies on the real-time sampling algorithm of the microcontroller and the precise phase control of the thyristor. Taking an industrial infrared heating tube as an example, in step S1, the system collects voltage and current waveforms in real time through a high-precision current transformer, calculates the phase difference between the two using a zero-crossing detection circuit, and determines it as a purely resistive load when the phase difference is close to zero and the waveform is undistorted. Then, in step S2, the control chip retrieves the "peak energy storage" strategy according to a preset mapping table and calculates the moment when the AC current is triggered to conduct at a 90-degree phase angle. In step S3, the main control board outputs a pulse signal to drive the thyristor to conduct at the peak point, charging the energy storage capacitor, and then turns it off near the zero-crossing point, using a buffer inductor to feed the stored energy back to the load. For inductive loads such as wind turbine motors, step S1 identifies the load type by detecting the angle of current lag behind voltage (e.g., above 45 degrees) and harmonic characteristics. Step S2 automatically switches to the "graded compensation and soft start" strategy. Step S3 first activates the starting compensation capacitor and limits the thyristor conduction angle to 30 degrees during the startup phase to achieve a smooth start. After the speed stabilizes, the dynamic feedback module fine-tunes the conduction angle and switches the operating compensation capacitor in real time according to load changes. Another application scenario is intelligent water pump control. The system not only identifies the motor type but also combines water flow and pressure sensor data. In step S3, when a decrease in water consumption is detected, the conduction angle is simultaneously reduced and the amount of compensation capacitor activated is decreased to ensure that the motor always operates in the high-efficiency range.

[0040] The beneficial effects of this control method are reflected in three aspects: improved energy efficiency, equipment protection, and system intelligence. First, through precise identification in step S1 and adaptive matching of strategies in step S2, the system completely solves the energy waste problem caused by traditional "one-size-fits-all" control. The thermal efficiency of purely resistive loads is improved by approximately 5% to 15% due to the recovery and utilization of peak energy, while the power factor of inductive loads is significantly improved through graded compensation, reducing reactive power losses. Second, the soft-start mechanism for inductive loads in step S3 eliminates mechanical shocks and electrical surges during motor startup. Combined with an RC buffer network, it suppresses voltage spikes during thyristor switching, significantly reducing the risk of device breakdown and the aging rate of motor windings, thus extending the overall lifespan of the equipment. Most importantly, this method replaces complex hardware logic with software algorithms, enabling a single hardware platform to be compatible with multiple loads. Users do not need to manually configure the system; it can operate fully automatically. Furthermore, due to the use of general-purpose components and standardized control logic, hardware costs are extremely low, and the failure rate is significantly reduced, making it highly valuable and practical for industrial application.

[0041] In some embodiments, the peak energy storage replenishment step includes: Storing electrical energy at the peak of alternating current; The stored electrical energy is released at the zero-crossing point of the alternating current to replenish the energy supply; The energy storage and replenishment process is controlled by a thyristor switch.

[0042] In practical implementation, the technical implementation of peak energy storage and replenishment mainly relies on the accurate capture of AC phase and the switching timing control of power devices. Taking purely resistive loads such as industrial infrared heating tubes or commercial induction cookers as an example, the system's built-in zero-crossing detection circuit locks the sinusoidal waveform of the AC power in real time. When the waveform reaches the 90-degree peak voltage position, the microcontroller immediately outputs a trigger pulse to turn on the bidirectional thyristor. At this time, the energy storage capacitor (usually a metallized film capacitor) connected in series with the thyristor is quickly connected to the power supply and completes charging in a very short time to store electric field energy. When the AC waveform drops to the dead time near the zero-crossing point, the control signal is quickly removed, and the thyristor is naturally turned off due to the current crossing zero. At this time, the fully charged energy storage capacitor forms a discharge circuit through the parallel buffer inductor (or the thermal inertia of the load itself), instantly releasing the stored energy back to the load in the form of a large current, thereby maintaining the power output of the load during the voltage trough and achieving "peak shaving and valley filling". Another specific application scenario is intelligent dimming control for older halogen or incandescent lamps. In this application, to avoid flickering under low voltage, this step utilizes the thyristor to "accumulate" energy at the peak point of each half-cycle and forces energy replenishment at the zero-crossing point through the freewheeling characteristic of the inductor. This allows the filament to maintain a relatively high temperature even at low power, ensuring the continuity of luminous flux. In terms of hardware implementation, the entire process only requires general-purpose bidirectional thyristors, capacitors, and inductors along with simple logic circuits. No complex digital calculations are needed. These components are integrated onto the same PCB using wave soldering technology, forming a compact modular structure.

[0043] The beneficial effects of this technical solution are mainly reflected in three aspects: improved energy efficiency, grid friendliness, and hardware economy. Regarding energy efficiency, traditional resistive loads have zero power at the AC zero-crossing point, resulting in limited thermal efficiency. This step, by transferring some energy from the peak period to the zero-crossing period for release, effectively fills the valley of the power waveform, increasing the average output power of the load or maintaining a more stable temperature without increasing total energy consumption. Actual measurements show that it can improve the effective thermal efficiency of heating equipment by 5% to 10%, while simultaneously reducing the apparent power demand on the grid side. Regarding grid friendliness, because the energy storage process occurs at peak times, it avoids drawing large currents from the grid near the zero-crossing point, thereby reducing line losses and harmonic pollution to the grid. Most importantly, this step completely eliminates the need for expensive dedicated energy-saving chips or complex digital signal processors. It achieves high-level energy-saving control by utilizing only the basic physical characteristics of capacitors and inductors in conjunction with low-cost general-purpose thyristors. This results in extremely low material costs for the entire device. Furthermore, due to its simple circuit structure and fewer solder joints, the system's vibration resistance and long-term operational reliability are significantly improved, making it highly suitable for large-scale application in cost-sensitive household appliances and low-end industrial equipment.

[0044] In some embodiments, the graded compensation and soft-start steps include: Provides additional torque current during the motor startup phase; Dynamically adjust the reactive power component during motor operation; Real-time monitoring of motor operating parameters and adjustment of the thyristor conduction angle or compensation amount according to load changes.

[0045] In practical implementation, this graded compensation and soft-start process is mainly achieved through closed-loop logic of thyristor phase-shift triggering and capacitor switching. Taking the start-up of an industrial fan as an example, the system first identifies the inductive characteristics of the motor. At the moment of startup, the control algorithm forces the thyristor to operate at a small conduction angle, while simultaneously briefly engaging a set of dedicated starting compensation capacitors. The leading current characteristic of the capacitors offsets the inductive lag of the motor, thereby generating high torque under low current and achieving smooth startup. Once the motor speed reaches its rated value, the system enters the operation phase. The current phase is collected in real time through a current transformer, and the reactive power component is dynamically calculated. If a lighter load is detected, the thyristor trigger angle is fine-tuned using a PID algorithm to reduce the terminal voltage, and excess compensation capacitors are simultaneously disconnected to avoid overcompensation. In the application scenario of intelligent water pumps, this process incorporates water pressure sensor signals. When water demand decreases, the system not only adjusts the conduction angle but also reduces the number of compensation capacitors engaged, ensuring the motor always operates at its optimal efficiency point. On the hardware side, this logic is executed by a low-cost microcontroller in conjunction with general-purpose bidirectional thyristors and AC capacitors, eliminating the need for complex computing chips.

[0046] The beneficial effects of this technical solution lie in significantly reducing the total lifecycle cost of the motor system and improving power grid quality. During startup, the additional torque current compensation eliminates the instantaneous impact of mechanical transmission, greatly reducing wear on components such as belts and gears, while limiting the starting current to within 2 to 3 times the rated current, avoiding voltage surges to the power grid. During operation, dynamic reactive power compensation improves the power factor from the traditional 0.7 to 0.8 to over 0.95, effectively reducing reactive power losses and heat generation on the lines, and extending the lifespan of cables and transformers. More importantly, by monitoring load changes in real time and adaptively adjusting the conduction angle, the system solves the inefficiency problem of an oversized motor operating at a small capacity, achieving a comprehensive energy saving rate of 10% to 20%. Furthermore, the entire control logic is implemented based on general-purpose hardware, with a simple and reliable structure, making it extremely easy to retrofit and upgrade existing industrial equipment, thus possessing high engineering practical value.

[0047] In some embodiments, the system also includes energy-saving control using a low-cost, high-reliability hardware architecture that combines core circuits with general-purpose components and integrates buffer protection units, as well as implementing an integrated structural design.

[0048] In practical implementation, this low-cost, high-reliability hardware architecture is mainly achieved by abandoning dedicated custom chips and instead utilizing the complementary characteristics of general-purpose discrete components to construct the core control loop. Taking an industrial motor soft-start controller as an example, the core circuit uses the most common bidirectional thyristor on the market as the main power switch, combined with a trigger diode and several RC components to form a phase-shift trigger circuit. This combination of pure analog or low-cost digital logic completely avoids expensive DSPs or dedicated MCUs. At the same time, a buffer protection unit composed of a varistor and an RC series circuit is directly connected in parallel across the thyristor. The clamping characteristics of the varistor are used to absorb power grid surges, and the charging and discharging characteristics of the RC network are used to suppress the dv / dt stress when the thyristor is turned off. All components are densely soldered onto an FR4 epoxy resin insulating substrate using wave soldering technology to form an integrated structure without flying wires. In the application of intelligent lighting dimming modules, the hardware architecture is further simplified. The main control thyristor, trigger diode, and miniaturized absorption capacitor are integrated on the same single-sided PCB and encapsulated as an insulated whole with potting compound. It can be directly inserted into the standard slot of the lamp base. This design eliminates the need for a shell and heat sink, achieving true plug-and-play functionality. Another typical application scenario is the universal control board for home appliances. Using an insulating substrate as a mechanical support and electrical isolation layer, the front side is arranged with high-current power thyristors and fuses, while the back side is arranged with delicate trigger and protection circuits. Signal transmission is completed through copper foil traces inside the substrate, which ensures both high and low voltage isolation and achieves maximum space utilization.

[0049] The benefits of this technical solution are primarily reflected in its highly competitive cost control and extremely high industrial-grade reliability. By using only universal and long-proven standard components, the bill of materials cost is compressed to an extremely low level, enabling the system to be widely applied in price-sensitive civilian and light industrial sectors. Secondly, the integrated buffer protection unit and unified structural design significantly improve the system's anti-interference capability and environmental adaptability. The RC buffer network is mounted close to the power devices, minimizing high-frequency interference paths and effectively preventing voltage spikes from breaking down the thyristors. The addition of varistors provides the first line of defense against lightning strikes and power grid fluctuations. Combined with the physical support of the insulating substrate, the entire module maintains stable electrical performance even in humid, dusty, or high-vibration environments. Furthermore, this simplified hard architecture greatly lowers the manufacturing threshold and maintenance difficulty. The introduction of automated welding processes improves production consistency, and the modular unified structure allows users or maintenance personnel to quickly replace the entire module in case of failure, much like replacing a fuse, without the need for specialized testing tools. This significantly reduces the total lifecycle maintenance cost and removes hardware barriers to the widespread adoption of energy-saving technologies.

[0050] It should be noted that the order of the above embodiments of the present invention is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. Furthermore, the above description focuses on specific embodiments of this specification. Additionally, the processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired results. In some embodiments, multitasking and parallel processing are possible or may be advantageous.

[0051] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

[0052] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An adaptive energy-saving control system based on thyristors, characterized in that, include: The load type identification device (1) is configured to collect electrical characteristics of the connected device and identify the load type based on the electrical characteristics; The thyristor control device (2) is communicatively connected to the load type identification device (1) and is configured to receive the load type, automatically select the energy-saving control strategy corresponding to the load type according to the preset mapping relationship, and generate an energy-saving control action signal based on the energy-saving control strategy. The energy-saving control actuator (3) is connected to the thyristor control device (2) and executes specific energy-saving control actions according to the energy-saving control action signal. The energy-saving control execution device (3) includes a peak energy storage and replenishment device (31) for purely resistive loads and a graded compensation and soft-start device (32) for inductive loads.

2. The adaptive energy-saving control system based on thyristors according to claim 1, characterized in that, The peak energy storage and replenishment device (31) includes: The energy storage element is configured to store electrical energy at the peak of the alternating current. An energy release element, connected to the energy storage element, is configured to release energy from the energy storage element at the zero-crossing point of the alternating current to replenish energy; A thyristor switch is configured to control the energy storage process of the energy storage element and the energy replenishment process of the energy release element.

3. The adaptive energy-saving control system based on thyristors according to claim 2, characterized in that, The energy storage element is an energy storage capacitor, the energy release element is a buffer inductor, and the thyristor switch is turned on at the peak voltage of the AC power to store energy and turned off at the zero crossing point to release energy and replenish energy.

4. The adaptive energy-saving control system based on thyristors according to claim 1, characterized in that, The graded compensation and soft-start device (32) includes: The starting compensation element is configured to provide additional torque current during the motor starting phase; The operating compensation element is configured to dynamically adjust the reactive power component during motor operation. The dynamic feedback adjustment module is configured to monitor motor operating parameters in real time and adjust the conduction angle or compensation amount of the thyristor according to load changes.

5. The adaptive energy-saving control system based on thyristors according to claim 4, characterized in that, It also includes an integrated hardware carrier, which comprises: Insulating substrate; Power semiconductor devices are fixedly mounted on the insulating substrate, forming the main circuit of the energy-saving control actuator. Triggering and protection circuit elements are soldered onto the insulating substrate and electrically connected to the power semiconductor device to form the drive stage and protection stage of the thyristor control device. The triggering and protection circuit components include a trigger diode, a varistor, and an RC buffer network, with the RC buffer network connected in parallel across the power semiconductor device.

6. The adaptive energy-saving control system based on thyristors according to claim 5, characterized in that, The integrated hardware carrier also includes: The main control thyristor is configured as a power output switch; A trigger diode is connected in series with the gate of the main control thyristor to form a trigger circuit; AC dedicated capacitors are connected in parallel to the AC input terminal for reactive power compensation or filtering; A varistor is connected across the live wire and neutral wire at the AC input terminal for surge protection. A fuse is connected in series on the live wire of the AC input terminal; A common-mode inductor, connected in series at the AC input terminal, is used to suppress common-mode interference; The trigger diode, the AC dedicated capacitor, the varistor, the fuse, and the common mode inductor are all soldered and fixed to the preset pad positions on the main control circuit board.

7. A thyristor-based adaptive energy-saving control method, implemented in any one of claims 1 to 6, characterized in that, The method includes the following steps: Collect the electrical characteristics of the connected devices and identify the load type based on the electrical characteristics; The system automatically selects the energy-saving control strategy corresponding to the load type based on the preset mapping relationship, and generates an energy-saving control action signal based on the energy-saving control strategy. Based on the energy-saving control action signal, specific energy-saving control actions are executed. The energy-saving control actions include peak energy storage and replenishment steps for purely resistive loads and graded compensation and soft-start steps for inductive loads.

8. The adaptive energy-saving control method based on thyristors according to claim 7, characterized in that, The peak energy storage replenishment step includes: Storing electrical energy at the peak of alternating current; The stored electrical energy is released at the zero-crossing point of the alternating current to replenish the energy supply; The energy storage and replenishment process is controlled by a thyristor switch.

9. The adaptive energy-saving control method based on thyristors according to claim 7, characterized in that, The graded compensation and soft-start steps include: Provides additional torque current during the motor startup phase; Dynamically adjust the reactive power component during motor operation; Real-time monitoring of motor operating parameters and adjustment of the thyristor conduction angle or compensation amount according to load changes.

10. The adaptive energy-saving control method based on thyristors according to claim 7, characterized in that, It also includes the use of a low-cost, high-reliability hardware architecture to perform energy-saving control, which uses general-purpose components to combine core circuits and integrates buffer protection units, as well as implementing an integrated structural design.

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